Needle making method and apparatus



Sept. 17, 1968 E. c. PETRY 3,401,723

NEEDLEMAKING METHOD AND APPARATUS Filed Aug. 8, 1966 2 Sheets-Sheet 1 HEDRAW v MEASURE STRAIGHTEN i TREAT CUT l SUPPLY REEL FIE 1 A STORAGE BINmllu "NIH W INVENTOR.

1 90420 C. Pa r/2y P 7, 1968 E. c. PETRY NEEDLEMAKING METHOD ANDAPPARATUS 2 Sheets-Sheet 2 Filed Aug. 8, 1966 TIMING CHART OFF OFF

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I T "I---- In- I I I 50 Iso 70 80 90 Ioo INTERVALS FOR 360 I Io 20 30 40CAM FUNCTION CARRIAGE RETURN DRIVE CLUTCH FAST DRIVE SLOW DRIVE WIRECLAMP HEAT TREAT CUT AC COMMON ALARM SENSE CAM NO.

o CALIBRATED IN Io% C AM ROTATION INVENTOR. 00430 6! Pzrey Ma/W UnitedStates Patent 3,401,723 NEEDLE MAKING METHOD AND APPARATUS Eduard C.Petry, Hopkins, Minn., assignor to Fabri-Tek Incorporated, Minneapolis,Minn., a corporation of Wisconsin Filed Aug. 8, 1966, Ser. No. 570,87615 Claims. (Cl. 140-140) ABSTRACT OF THE DISCLOSURE A needlemakingmethod and apparatus having a movable carriage for drawing a wirethrough a clamp and guide unit. The carriage has a pair of gripping jawswhich are opened by wedge shaped cams to grasp and release the wire.Near the end of the draw, the wire is heat treated and straightenedunder tension. The grasping cam is also a contact member which movesinto engagement with the portion of the wire adjacent the clamp andguide unit. A cut voltage applied to the contact member heats the wirevery hot at the point of engagement with the contact member so that thetension on the wire established by the movable carriage elongates theheated point until the wire breaks. After the wire is broken it isreleased from the jaws by the action of the release cam and deposited ina container.

Summary of invention This invention relates to a method and apparatusfor automatically making linear needles usable to string drivelines andsense-lines through a magnetic core memory plane.

Wire needles are used in the magnetic core memory art for stringing thedrive-lines and sense-lines through the small openings in the rows ofmagnetic cores. These needles are fairly rigid and have forward tipswhich are rounded or bullet-nosed so as to reduce the likelihood of theforward ends from catching on the edge of one or more of the cores asthe string operation proceeds. In practice, each needle is a one timearticle being used only for a few passes through the core matrix andthen discarded. The lines are attached to the trailing end of the needleby a butt weld whereby the needle functions to thread the lines throughthe cores.

The method and apparatus of this invention automatically produces alarge quantity of needles at a low cost in a minimum of time. Theseneedles have the desired physical characteristics of hardness andstraightness as well as a bullet-nose shape on both ends.

Briefly summarized, the invention converts ordinary fine steel wire intostandard length needles having a bullet-nose shape at both ends. Theapparatus handles the wire stock in five individual steps. Initially theforward end of the wire is grasped and then pulled from a supply reel.Wire is drawn through a guiding orifice to a predetermined length. Nearthe end of the drawing the wire is straightened by simultaneouslyapplying tension and heat treat voltage to the wire. This straightensand tempers the wire. A cut voltage is applied to a section of the endof the wire remote from the forward end of the wire thereby severing thedrawn section of the wire from the reel. The cut voltage and tension onthe wire rounds the ends of the wire into a bullet-nose shape. After thewire has been cut, it is deposited into a storage location.

The apparatus has .a clamp unit for guiding and applying a holding forceon the wire as it unwinds from a supply reel. A carriage having a pairof movable jaws moves toward and away from the clamp unit by a drivemeans. An actuator located adjacent the clamp unit is operable to openthe jaws to permit the jaws to grip the 3,401,723 Patented Sept. 17,1968 forward end of the wire projected from the clamp unit. The drivemeans moves the carriage away from the clamp unit drawing the wire in anelongated linear path. When the carriage approaches the end of itsforward travel, the clamp means applies a holding force on the wirethereby placing the wire under tension. Simultaneously with the.actuation of the clamp means, the actuator means functions as anelectrical contact whereby the drawn section of the wire is placed in anelectrical circuit. The voltage applied to the wire is sufficient toheat the wire to a dull red glow. With the wire under tension and heatedit is straightened and annealed in the red glow condition. The wire isthen air quenched by sharply cutting the voltage. This hardens the wire.The wire is cut by raisng the actuator means into contact with the wireand applying a cutting voltage to the wire. The cut voltage is appliedbetween the clamp unit and the actuator with the actuator on the hotside of the voltage. The result is that the wire is heated very hot butnot to a melt at the point that the actuator contacts the Wire. Thecontinued tension on the wire from the outward movement of the carriagepulls the heated point out very thin until it eventually snaps leavingthe broken ends with a bullet-nose shape. After the wire is cut it isreleased from the jaws and deposited in a storage location. Thesequential operation of the drive means for the carriage, the clamp unitand actuator are under the control of a timer which automaticallycontrols the apparatus.

In the drawings.

FIGURE 1 is a block diagram of the operation sequence of theneedlemaking apparatus and method of this invention;

FIGURE 2 is a diagrammatic plan view of the needlemaking apparatus ofthe invention showing the wire drawing carriage in the needle releaseposition;

FIGURE 3 is a fragmentary plan view partly sectioned of the needlemakingapparatus showing the wire drawing carriage in the wire pick up orreference position;

FIGURE 4 is a perspective view of the stationary clamp and guide unit;

FIGURE 5 is a perspective view of the wire gripping jaws mounted on thewire drawing carriage body;

FIGURE 6 is a perspective view of the jaw actuating cam;

FIGURE 7 is a view similar to FIGURE 6 showing the jaw actuating camrotated to the non-operative position; and

FIGURE 8 shows the timing chart for the operation of the needlemakingapparatus.

Referring to the drawings, there is shown in FIGURE 1 the major steps ofthe needlemaking operation of this invention. Wire is drawn from asupply reel to a measured length. When the desired length of wire isreached the wire is simultaneously electrically heat treated and placedunder tension to straighten the drawn length of wire. The wire is cut byan electrode which contacts the wire heating it to a temperature so thatcontinued tension on the wire causes it to break at a desired length.After the wire is cut, it is discharged into a storage bin.

As shown in FIGURES 2 and 3, the apparatus 10 of this invention convertswire 12, as XLO Bright Music Wire, into standard 8 inch lengths or otherlengths suitable for needles. The wire may have a diameter from .003 to.010 inch. The method of heat treat is applicable to high carbon ferricalloy wire which can be heated and air quenched for hardness. Theapparatus is not limited to this particular wire or wire size, as othertypes and sizes of electrically conductive wire may be used. The wire 12is pulled through clamp and guide unit 14 by a movable carriageindicated generally at 16 having a pair of gripping jaws 17 and 18.Carriage 16 has a pair of bearings 19 and 20 connected with a transverseupright block or body 21. Bearings 19 and 20 are slidably mounted onelongated parallel rails 22 and 23 secured at their opposite ends totransverse upright supports 24 and 26 mounted to table 11.

As shown in FIGURE 5, jaws 17 and 18 are located adjacent the forwardside of block 21. A pin 28 projected through the upper portion of jaw 17threaded into block 21 pivotally mounts the jaw on the block. In asimilar manner, pin 29 pivotally mounts jaw 18 on block 21. The lowerfacing sides of jaws 17 and 18 are biased together with a spring 31connected to each of the jaws below pins 28 and 29. To increase thegripping act-ion and reduce wear, hard metal inserts 32 and 33 aremounted in the adjacent faces of the lower ends of jaws 17 and 18. Thespace between inserts 32 and 33 is a wire gripping area 34.

A drive mechanism indicated generally at 36 is operable to reciprocatecarriage 16 along rails 22 and 23 as indicated by arrow 37. Drivemechanism 36 comprises a first electric motor 39 drivably coupled to aclutch 41. An endless chain 42 trained about sprockets 43 and 44 extendsparallel to rail 22 and is drivably coupled to the output of clutch 41.A coupling 46 is used to connect the carriage to a portion of chain 42whereby on movement of the chain carriage 16 moves along rails 22 and23. A second electric motor 40 drivably coupled to sprocket 43 is usedto return the carriage to the wire pick up or reference positionadjacent the forward side of clamp unit 14.

Clamp and guide unit 14, shown in FIGURE 4, has a lower block member 47and an upper block member 48 movably mounted on an upright plate 49.Unit 14 is electrically insulated from and mounted on table 11. Themidportion of plate 49 has a hole 51 for guiding the wire as it movesbetween the upper and lower members. A solenoid 52 connected to uppermember 48 operates to move the upper member toward and away from thelower member to hold and release the wire between the members 47 and 48.As shown in FIGURE 2, an elongated tube 53 extends from clamp and guideunit 14 toward spool 13. Tube 53 coacts with the hole 51 in the plate 49to guide the wire 12 straight between upper and lower members 47 and 48.Located between tube 53 and spool 13 is a wire cleaning unit 54, as awick saturated with alcohol. Returning to FIGURES 2 and 3, with the jaws17 and 18 in gripping engagement with the forward end of wire 12,movement of the carriage 16 away from clamp unit 14 draws the wirethrough the clamp unit toward the forward or remote end of theapparatus. After measuring, heat treating and cutting the wire, thecarriage 16 approaches support 26 and jaws 17 and 18 engage a wedgeshaped cam 56 secured to table 11. As the jaws move over the cam theyare spread or snapped open allowing the needle which has been previouslycut to drop through a delivery slot 57 in the table 11 into a storagebin located below the table.

As soon as the needle has been released from jaws 17 and 18 carriage 16returns to its initial or reference position adjacent the forward sideof clamp and guide unit 14. As the carriage 16 approaches the clamp andguide unit 14 jaws 17 and 18 engage an actuator indicated generally at58 which operates to open the jaws allowing them to grip the forward endof the previous cut wire 12 projected from the clamp and guide unit 14.

As shown in FIGURE 6, actuator 58 comprises an arm 59 having atransverse pin 61 at one end thereof pivotally mounting the arm on table11. Arm 59 moves in up and down directions as indicated by arrow 62about the axis of pin 61. A solenoid 63 connected to the end of arm 59opposite the transverse pin 61 is operable to raise and lower arm 59.One side of arm 59 has a rectangular cut out or groove 64 providing aspace for a block 66 carrying a wedge shaped cam 67. A transverse pin 68pivotally mounted block 66 to the side of arm 59 thereby holding theblock in cut out 64. Secured to and projected downwardly from block 66is an elongated finger 69 connected to one end of a coil spring 71. Theother end of spring 71 is connected to a support 72 thereby biasingblock 66 against the outer wall of the arm 59 positioning wedge cam 67in the horizontal plane of the top of the arm. As shown in FIGURE 7,block 66 has an arcuate back 73 which allows the block 66 to rotateabout pin 68 against the biasing force of spring 71 moving the wedgeshaped cam 67 downwardly into cut out 64. With cam 67 in cut out 64 thewire gripping jaws move over back 73 and do not jam against backside 88of cam 67.

The operation of the needlernaking apparatus 10 is under the control ofa timer, indicated generally at 74, which consists of an array of sevenrotating cams 76 mounted on a common motor driven shaft 77. The camssequentially operate switches (not shown) which control electricalcircuits to the motors 39 and 40, solenoid 52 and 63, as well as thewire heat treatment and electrical cutting circuits. The timing chartshown in FIGURE 8 illustrates the entire operation of the timer. Thehorizontal time-scale is divided into ten equal parts each representingapproximately 10% of the total cycle. The vertical data is the sevenactive cams of the timer. Cams No. 3 and No. 4 are dual functioning inthat the operate switches serving to sequentially actuate the returnmotor 40 and the electric clutch 41 to the main forward drive motor 39as well as switches operable to change the motors from fast to slowspeeds and back again.

The wire threaded into the apparatus through tube 53 and hole 51 inplate 49 positions a portion of the wire between members 47 and 48 ofthe clamp and guide unit 14. A short length of wire, projects forwardlyfrom plate 49 so that it can be gripped by jaws 17 and 18. This placesthe apparatus in condition for automatic operation.

The carriage 16 is driven at a fast speed hack to its pick up positionby return motor 40. Cam No. 3 actuates the return motor 40 and theelectric clutch 41 to release the drive of motor 39. Solenoid 52 isenergized by operation of cam No. 7 thereby clamping the wire betweenthe upper and lower members 47 and 48. As carriage 16 reachesapproximately the last two inches of return travel a braking cam 79mounted on hearing 20 intercepts a switch 81 which engages the mainforward drive motor 39 to brake the speed of the carriage. The momentumof the carriage is such that the forward motor only brakes the drivingchain and carriage preventing the carriage from slamming into jawactuating cam 67. The forward portion or point of cam 67 is in alignmentwith the wire gripping area 34 between the jaws 17 and 18 so that ascarriage 16 moves toward clamp and guide unit 14 cam 67 spreads thejaws. Further movement of the carriage locates the jaws on oppositesides of the forward end of the wire projected from unit 14. As soon asjaws 17 and 18 have moved over cam 67 the spring 31 snaps the jaws shuton the forward end of the wire.

When jaws 17 and 18 are snapped shut pinching the protruding end of thewire between the jaws, return motor 40 is turned off by cam No. 3.Simultaneously cam No. 3 actuates electric clutch 41 engaging the maindrive to driving chain 42 at a fast speed. Carriage 16 starts itsoutboard trip pulling with it the wire held by jaws 17 and 18. Cam No. 7actuates a switch which de-energizes solenoid 52 of the clamp and guideunit 14 thereby releasing the grip on the wire so that it can be freelydrawn through hole 51. Supply reel 13 is retarded by a continuousfriction brake operating on the opposite shafts of the reel. Thisprevents the wire from unwinding when the travel of carriage 16 showsdown and terminates.

As wire 12 is drawn out to nearly the desired length, cam No. 4 on thetimer shifts the main drive motor voltage to slow speed. Simultaneouslycam No. 7 on the timer actuates solenoid 52 forcing the plate members 47and 48 into frictional engagement with the wire thereby putting a dragon the wire. Continued forward movement of the carriage places the wireunder tension. At the same time, cam No. 5 on the timer applies the heattreated voltage,

for example 22 volts, to the drawn wire. The circuit is completed withlines 82 and 83 connected to the carriage and clamp and guide unit 14respectively. The flow of current through the needle portions 78 of wire12 heat treats the wire by elevating the temperature of the wire to adull red glow. With the wire under tension the heating takes allcurvatures out of the wire providing a straight linear needle andprovides the needle with a gun bluing oxide coat which is a rustinhibitor.

Cam No. 5 operates to cut off the heat treat voltage while cam No. 6applies the cut voltage to line 84 connected to the finger 69 of theactuator 58. Cam No. 6 also actuates the solenoid 63 which rotates theactuator arm 59 in an upward direction forcing the rearward transverseedge 88 of the wedge shaped cam 67 into physical contact with theportion of the wire projected forwardly from plate 49. Solenoid 52 ofclamp unit 14 is still energized and the drive motor 39 is still drivingat a slow drive speed. A cut voltage is applied between the cam 67 andan AC common ground connected to clamp plates 47 and 48. The hot side ofthe cut voltage is on cam 67 so that the wire is heated very hot at thepoint of contact with the cam. The continuing tension on the wire fromthe drive mechanism 36 pulls the heated point out very thin until iteventually snaps. The result is that both ends of the broken wire haveacquired a bullet-nose shape.

Cams No; 2 and No. 6 disconnect the cut voltage from the AC commonground. Simultaneously cam No. 1 turns on an alarm sense voltage whichtests for ground voltage between a brass plate 86 located adjacent theactuator 58 and clamp unit 14. If the wire is properly cut its rearunclamped end will contact the plate establishing a circuit. If for anyreason the cut was not accomplished or if the jaws 17 and 18 do not gripand draw out a wire, the circuit will not be completed and an alarm willsound causing the apparatus to stop. Once the apparatus has stopped dueto failure of an operation, it will remain idle until the operatorrestarts it after correcting the fault.

Once the apparatus has established a successful cut cam No. 4 returnsthe main drive motor to the fast drive speed. Carriage 16 continues itsoutward travel until it strikes the needle release cam 56 which opensjaws 17 and 18 allowing the needle to drop through slot 57 in the tableinto a storage bin. At the same moment, carriage 16 encounterssynchronizing switch 87 which serves to deactivate the electric clutch41 in case carriage 16 is not synchronized with the other components ofthe machine. If carriage 16 is ahead of the timer, it will be delayeduntil a lobe on cam No. 3 engages the return cam drive switch startingthe cycle over again.

In terms of a method of making needles from metal wire the inventionincludes the steps of holding the forward portion of the wire with theend of the wire being free and gripping the forward end of the wire withthe jaws 17 and 18 on movable carriage 16. Movement of carriage 16 drawsthe wire through guide and clamp unit 14 in an elongated linear path toa predetermined length. Near the end of the drawing operation the drawnwire is straightened by simultaneously applying tension and a heat treatvoltage to the drawn wire. If straight pre-heat treat wire is fed intothe apparatus the heat treat cycle may be omitted. The wire is drawn ata first fast speed and then at a second slow speed. The tension and heattreat voltage is applied to the wire during the slow speed drawingoperation. After the wire is heat treated it is cut at a section remotefrom the forward end of the wire by applying a cut voltage to the wire.The wire is drawn and therefor under tension while it is being cut toprovide the end of the wire with a bullet-nose shape. After the wire iscut it is deposited in a storage location.

The foregoing disclosure relates to a preferred embodimeut of theinvention and is intended to cover all changes and modifications whichdo not depart from the spirit and the scope of the invention. Theinvention is defined in the following claims.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as follows:

In the claims:

1. An apparatus for making needles from wire comprising: first means forapplying a holding force on the wire, a carriage movable toward and awayfrom the first means, second means mounted on the carriage for grippinga forward end of the wire projected from the first means, actuator meanslocated adjacent said first means engageable by the second means toplace the second means in gripping engagement with the forward end ofthe wire, drive means for moving the carriage away from the first meansthereby drawing the wire relative to the first means, electric heatapplying means for heat treating the drawn wire, electric means forheating the wire adjacent the first means, said electric means includinga contact member located forwardly of the first means and engageablewith the wire, and circuit means for applying a cut voltage to thecontact member whereby the wire is heated very hot at the point ofengagement with the contact member and the tension on the wire,established by the movable carriage, elongates the heated point untilthe wire breaks, and means for releasing the forward end of the cut wirefrom the second means, said drive means returning the carriage towardthe first means after the wire has been released from the second means.

2. The apparatus of claim 1 wherein said first means includes a pair ofplate members and power means for selectively holding the plate means inengagement with the wire.

3. The apparatus of claim 2 wherein said power means is a solenoid.

4. The apparatus of claim 1 wherein the second means comprises a pair ofjaws, means pivotally mounting the jaws on the carriage, and means forbiasing the jaws together whereby the forward end of the wire is grippedbetween the jaws.

5. The apparatus of claim 4 wherein the actuator means includes a wedgeshaped cam engageable with the jaws to spread said jaws whereby the jawsgrip the forward end of the wire.

6. The apparatus of claim 1 wherein the actuator means includes a wedgeshaped cam engageable with the second means allowing the second means tomove in gripping relation with the forward end of the wire.

7. The apparatus of claim 1 wherein said drive means includes a firstmotor for driving the carriage away from the first means and a secondmotor for returning the carriage to its reference position adjacent thefirst means, and a timer for controlling the drive means in sequencewith the electric heat applying means and the electric cut means wherebythe wire is sequentially drawn, straightened and heat treated, cut andreleased for discharge to a storage location.

8. The apparatus of claim 1 including a timer for controlling the drivemeans in time sequence with the first means for applying a holding forceon the wire, electric heat applying means and electric cut means wherebythe wire is sequentally drawn, straghtened and heat treated, cut andreleased for discharge to a storage location.

9. The apparatus of claim 1 including motor means engageable with theactuator means for moving the actuator means into contact with the wire,said actuator means having an electrical contact for the electric cutmeans.

10. The apparatus of claim 1 wherein the first means and the carriageprovide electrical contacts for the electric heat applying means wherebyelectricity is conducted through the length of wire extended from thefirst means to the carriage.

11. The apparatus of claim 2 wherein the means for releasing the forwardend of the cut wire from the second means comprises a stationary wedgeshaped cam engageable with the jaws to spread the jaws on movement ofthe carriage relative to the cam.

12. A method of making needles from metal wire comprising the steps of:gripping the forward end of a wire, drawing the wire in an elongatedlinear path, straightening the drawn wire by simultaneously applyingtension and a heat treat voltage to the wire and cutting the wire bysimultaneously applying tension to the wire and a cut voltage to asection of the Wire remote fom the forward end of the wire whereby thewire is heated very hot at said section and the tension on the wireelongates the heated section until the wire breaks.

13. The method of claim 12 wherein said wire is drawn at a first fastspeed and a second slow speed, said tensio-n and heat treat voltagebeing applied to the wire when the wire is drawn at said second slowspeed.

14. The method of claim 12 wherein the cut length of wire is depositedin a storage location.

15. The apparatus of claim 1 wherein the actuator 8 means comprise acontact member movable mounted forwardly of the first means, means formoving the contact member into engagement with the wire, said circuitmeans applying a cut voltage to the contact member.

References Cited UNITED STATES PATENTS 344,819 7/ 1886 Eckerson 140-1401,169,819 2/1916 Henderson 72-364 1,661,866 3/1928 Zabel 140-1402,667,557 1/ 1954 Herzog 219-68 2,679,570 5/1954 Cisne 219-68 CHARLES W.LANHAM, Primary Examiner. L. A. LARSON, Assistant Examiner.

